Method for producing an automotive friction material with optimized multi dimensional construction

ABSTRACT

A method for producing an automotive friction material with optimized multi-dimensional construction includes receiving a base friction-disc material, cutting the base friction-disc material to a predetermined size and shape, assembling the sized and shaped cut base friction-disc material, bonding the base friction-disc material to a base friction plate, and utilizing a multi nozzle printing array to deposit friction enhancing materials overtop a reaction surface of the base friction-disc material.

INTRODUCTION

The statements in this section merely provide background informationrelating to the present disclosure, and may not constitute prior art.

The present disclosure relates to motor vehicles, and more specificallyto methods of producing friction materials used in motor vehicletransmission components. Friction materials are used in a variety oflocations within motor vehicles, and in particular in transmissioncomponents such as clutches, synchronizers, torque converter clutches,and multi-plate clutch packs. Each of the clutch disks and/orsynchronizers used in a motor vehicle transmission is typicallyconstructed of fibrous materials, some form of resinous material, andadditives. The quantities and proportions of the additives can be usedto modify wear, friction, and thermal properties of the clutch disksand/or synchronizers, depending on the application for which the clutchdisks and/or synchronizers are designed. As transmission technologieshave advanced, to provide more rapid and smoother shifts between gears,tolerances of the transmission components have become more important tothe design and construction of the transmission. Moreover, thecomplexity of the transmission and of transmission components hasincreased. As a result, while traditional methods for depositing fibrousmaterial, resinous material and additives are effective for theirintended purpose, there is a need in the art for new and improvedmethods of producing automotive friction materials that more accuratelycontrol the multi-dimensional distribution of fibrous material, resin,and additives over the clutch disks and/or synchronizers, whiledecreasing manufacturing complexity and costs.

SUMMARY

According to several aspects a method for producing an automotivefriction material with optimized multi-dimensional construction includesreceiving a base friction-disc material, cutting the base friction-discmaterial to a predetermined size and shape, assembling the sized andshaped cut base friction-disc material, bonding the base friction-discmaterial to a base friction plate, and utilizing a multi nozzle printingarray to deposit friction enhancing materials overtop a reaction surfaceof the base friction-disc material.

In another aspect of the present disclosure receiving the basefriction-disc material further includes receiving a continuous roll orflattened stock forming the base friction-disc material.

In another aspect of the present disclosure the base friction-discmaterial is a woven material.

In another aspect of the present disclosure the base friction materialis a composite material.

In another aspect of the present disclosure cutting the basefriction-disc material further includes utilizing a die to cutinterlocking arcuate segments or annular rings of base friction-discmaterial from the base friction-disc material.

In another aspect of the present disclosure assembling the sized andshaped cut base friction-disc material further includes connectinginterlocking arcuate segments to form complete annular rings of basefriction-disc material.

In another aspect of the present disclosure bonding the basefriction-disc material to the base friction plate further includesinjecting a bonding material between the base friction-disc material andthe base friction plate.

In another aspect of the present disclosure utilizing a multi nozzleprint array further includes providing a supply of a plurality offriction enhancing materials to nozzles of the print array, wherein theplurality of friction enhancing materials include friction modifiers andresins.

In another aspect of the present disclosure utilizing a multi nozzleprint array further includes depositing structural resin to precisepredetermined locations on the base friction-disc material in a highdensity linear printing process or a translational printing process.

In another aspect of the present disclosure a method for producing anautomotive friction material with optimized multi-dimensionalconstruction further includes dynamically adjusting material propertiesof the friction enhancing materials as the multi nozzle print arraydeposits the friction enhancing materials on the reaction surface of thebase friction-disc material.

In another aspect of the present disclosure dynamically adjustingmaterial properties of the friction enhancing materials further includesactively and dynamically controlling a duration of deposition, aviscosity, a density, and a flow speed or flow rate of the frictionenhancing materials through the multi nozzle print array.

In another aspect of the present disclosure utilizing a multi nozzleprint array to deposit friction enhancing materials overtop a reactionsurface of the base friction-disc material further includes dynamicallyadjusting a depth of the friction enhancing materials as the frictionenhancing materials are deposited on the base friction-disc material.

In another aspect of the present disclosure a method for producing anautomotive friction material with optimized multi-dimensionalconstruction includes receiving a continuous roll or flattened stockbase friction-disc material composed of a woven carbon material or acomposite material, cutting the base friction-disc material to apredetermined size and shape, the predetermined size and shape beinginterlocking arcuate segments or annular rings of base friction-discmaterial cut from the base friction-disc material, and utilizing a multinozzle printing array to deposit friction enhancing materials overtop areaction surface of the base friction-disc material at precise locationson the base friction-disc material.

In another aspect of the present disclosure a method for producing anautomotive friction material with optimized multi-dimensionalconstruction further includes assembling the annular rings or assemblingthe interlocking arcuate segments to form annular ring, and utilizing abonding material between the annular rings of base friction-discmaterial and a base friction plate to permanently bond the annular ringsof base friction-disc material to the base friction plate.

In another aspect of the present disclosure utilizing a multi nozzleprint array further includes providing a supply of a plurality offriction enhancing materials to nozzles of the print array, wherein theplurality of friction enhancing materials include friction modifiers andresins.

In another aspect of the present disclosure utilizing a multi nozzleprint array further includes depositing a structural resin at precisepredetermined locations on the base friction-disc material in a highdensity linear printing process or a translational printing process, anddynamically adjusting a duration of deposition, a viscosity, a density,a flow speed or flow rate, and a material composition of the frictionenhancing materials as the multi nozzle print array deposits thefriction enhancing materials on the base friction-disc material.

In another aspect of the present disclosure a method for producing anautomotive friction material with optimized multi-dimensionalconstruction further includes dynamically adjusting a depth of thefriction enhancing materials as the friction enhancing materials aredeposited on the base friction-disc material.

In another aspect of the present disclosure utilizing a multi nozzleprint array further includes depositing a structural resin into jointsbetween interlocking arcuate segments of base friction-disc material.

In another aspect of the present disclosure a method for producing anautomotive friction material with optimized multi-dimensionalconstruction includes receiving a continuous roll or flattened stockbase friction-disc material composed of a woven carbon material or acomposite material, cutting the base friction-disc material to apredetermined size and shape, the predetermined size and shape beinginterlocking arcuate segments or annular rings of base friction-discmaterial cut from the base friction-disc material, bonding the annularrings to a base friction plate, or assembling the interlocking arcuatesegments to form annular rings and bonding the resulting annular ringsto the base friction plate by utilizing a bonding material between theannular rings of base friction-disc material and the base friction plateto permanently bond the annular rings of base friction-disc material tothe base friction plate, providing a supply of a plurality of frictionenhancing materials to nozzles of a multi nozzle print array, whereinthe plurality of friction enhancing materials include friction modifiersand resins, utilizing the multi nozzle printing array to deposit astructural resin at precise predetermined locations on the basefriction-disc material in a high density linear printing process or atranslational printing process, and dynamically adjusting a duration ofdeposition, a viscosity, a density, a flow speed or flow rate, and amaterial composition of the friction enhancing materials as the multinozzle print array deposits the friction enhancing materials on the basefriction-disc material, and dynamically adjusting a depth of thefriction enhancing materials as the friction enhancing materials aredeposited on the base friction-disc material. The multi nozzle printingarray deposits friction enhancing materials overtop a reaction surfaceof the base friction-disc material.

In another aspect of the present disclosure utilizing a multi nozzleprint array further includes depositing a structural resin into jointsbetween interlocking arcuate segments of base friction-disc material.

Further areas of applicability will become apparent from the descriptionprovided herein. It should be understood that the description andspecific examples are intended for purposes of illustration only and arenot intended to limit the scope of the present disclosure.

BRIEF DESCRIPTION OF THE DRAWINGS

The drawings described herein are for illustration purposes only and arenot intended to limit the scope of the present disclosure in any way.

FIG. 1A is a plan view of a segment of a clutch disk manufacturedaccording to an aspect of the present disclosure;

FIG. 1B is a cross sectional view of the segment of clutch disk of FIG.1A taken across line A-A and shown during a manufacturing step of themethod according to an aspect of the present disclosure;

FIG. 1C is a partial cross sectional depiction of the clutch disk ofFIG. 1A taken across line A-A and shown in use in a motor vehicletransmission according to an aspect of the present disclosure;

FIG. 2A is a plan view of a segment of another clutch disk manufacturedaccording to an aspect of the present disclosure;

FIG. 2B is a cross sectional view of the segment of clutch disk of FIG.2A taken across line B-B and shown during a manufacturing step of themethod according to an aspect of the present disclosure;

FIG. 2C is a partial cross sectional depiction of the clutch disk ofFIG. 2A taken across line B-B and shown in use in a motor vehicletransmission according to an aspect of the present disclosure;

FIG. 3A is a plan view of a segment of another clutch disk manufacturedwith localized three dimensional ink according to an aspect of thepresent disclosure;

FIG. 3B is a cross sectional view of the segment of clutch disk of FIG.3A taken across line C-C and shown during a manufacturing step of themethod according to an aspect of the present disclosure;

FIG. 4A is a plan view of a segment of another clutch disk manufacturedwith axial strength and friction modifications according to an aspect ofthe present disclosure;

FIG. 4B is a cross sectional view of the segment of clutch disk of FIG.4B taken across line D-D and shown during a manufacturing step of themethod according to an aspect of the present disclosure; and

FIG. 5 is a flowchart depicting a method of producing a clutch diskaccording to an aspect of the present disclosure.

DETAILED DESCRIPTION

The following description is merely exemplary in nature and is notintended to limit the present disclosure, application, or uses.

Friction-disc clutch mechanisms are commonly used at a variety oflocations throughout a motor vehicle's powertrain to transfer motivepower between a driving shaft and a driven shaft. The operation of suchclutch mechanisms generally includes pressing together a pair of opposedclutch plates in which one plate has a high-friction contact surface andthe other plate has a relatively smooth contact surface. The forcefulengagement between the high friction plate and the smooth plateinterlocks the plates together and causes both plates to rotate inunison to achieve a desired power transfer. Under certain clutchoperating conditions, however, the constant engagement and disengagementof the plates can be approximated by a stick-slip phenomenon in whichthe plates skid against one another as opposed to cleanly and crisplyengaging and disengaging. Such stick-slip situations are commonlyreferred to as clutch shudder. To address this, and other relatedissues, such as wear and noise, a multi-layer coating for application toat least a smooth plate surface of a friction-disc clutch mechanism hasbeen developed. FIGS. 1A-4B illustrate a series of examples of such afriction-disc generally shown and indicated by reference number 10. Eachof the examples of FIGS. 1A-4B can be produced as an arcuate segment ofthe friction-disc 10. However, in some examples the friction-disc 10 isformed as a complete annular disc 11 without interruption, while inother examples, the friction-disc 10 is formed of a series ofinterlocking arcuate segments in fixed engagement with one another.

FIGS. 1A-10, do not expressly depict an automatic transmission or amanual transmission clutch assembly, however, an automatic transmissiontorque converter clutch of the variety shown in FIGS. 1A-10 would be asingle-plate design. However, it should be appreciated that multipleplate torque converter clutches and/or multiple-plate manualtransmission clutches may include substantially the same components asdescribed herein without departing from the scope or intent of thepresent disclosure.

In the example of FIGS. 1A-10, a segment of a friction-disc 10 accordingto an aspect of the present disclosure is shown. The friction-disc 10 isa substantially planar, annular disc 11 composed of a plurality oflayers. A base friction plate 12 forms a base portion of thefriction-disc 10. The base friction plate 12 is relatively rigid andcomposed of a metallic compound such as steel. The base friction plate12 may in some instances, however, allow a predetermined amount ofbending or deflection according to the design requirements of theparticular powertrain location in which the friction-disc 10 is to beused. The base friction plate 12 supports a base layer 14. In severalaspects, the base layer 14 is composed of fibrous materials, such ascarbon fibers or the like. The fibrous materials are used in a varietyof forms, such as a woven carbon fabric. In the example of FIGS. 1A-10,the woven carbon fabric of the base layer 14 is shown as having asubstantially orthogonal or “square” weave having first carbon fibers 16woven orthogonally with second fibers 18. While the exemplary wovencarbon fabric of FIGS. 1A-10 is square-woven, it should be understoodthat depending on the application, cost constraints, and desirablefrictional characteristics may dictate that the woven carbon fabric mayhave other woven patterns such as twill, satin, basket weave, jacquard,dobby, leno, or the like without departing from the scope or intent ofthe present disclosure. However, while the woven carbon fabric of thebase layer 14 may provide coefficients of friction in some applications,in other applications it is desirable to increase, decrease, orotherwise modify the coefficient of friction of the carbon fabric of thebase layer 14.

Accordingly, FIG. 1B depicts a cross section of FIG. 1A taken acrossline A-A during a manufacturing step. During production a multi-nozzleprint head or print array 20 deposits a plurality of additives 24overtop the base layer 14. The print array 20 is a high density linearprint head capable of print, injecting, or otherwise depositing theplurality of additives 24 either simultaneously, or sequentially. Theprint array 20 has a plurality of nozzles 22 in fluid communication withat least one pump (not shown) and an additive 24 reservoir (not shown).The print array 20 is both mechanically and digitally controlled. Thatis, the print array 20 includes a plurality of mechanical features suchas pumps, valves, and the like (not shown). Moreover, the print array 20includes a plurality of electronic control features such as computerizedprint array 20 controllers (not shown). In several aspects, thecomputerized print array 20 controllers are non-generalized, electroniccontrol devices having a preprogrammed digital computer or processor(not shown), memory or non-transitory computer readable medium (notshown) used to store data such as control logic, instructions, imagedata, lookup tables, etc., and a plurality of input/output peripheralsor ports (not shown). The processor is configured to execute the controllogic or instructions, and generate outputs to the print array 20, andthereby the friction-disc 10. The controller may have additionalprocessors or additional integrated circuits in communication with theprocessor, such as perception logic circuits for analyzing visual datarelating to the friction-disc 10 or other such integrated circuitry.

The nozzles 22 may take a variety of forms depending on the particularapplication. In some examples, each of the nozzles 22 has a fixed sizeand generates a fixed spray pattern 23. In other examples, some or allof the nozzles 22 in a given print array 20 may have varying sizesand/or dynamically variable sizes and thereby generate a variety ofdifferent spray patterns 23. Additionally, in some examples theadditives 24 supplied to the nozzles 22 of the print array 20 arepressurized to assist the print array in generating a predeterminedspray pattern 23 with desirable characteristics for a given application.

In some aspects, the plurality of additives 24 impregnate and bond tothe carbon fabric of the base layer 14, while in other aspects, theplurality of additives 24 remain substantially on a surface of the firstand/or second fibers 16, 18 of the carbon fabric of the base layer 14.The plurality of additives 24 include resins 26, friction modifiers 28,and the like. In some aspects, the resins and friction modifiers 26, 28are customized for and specific to a particular friction-disc 10application. That is, the composition of each of the resins 26, andfriction modifiers 28 varies depending on the application for which thefriction-disc 10 is to be used. In some examples, the friction modifiers28 include types of resin 26, particulates, and/or organic frictionmodifiers, or the like. In some examples, the resins 26 used atintersections between the first and second fibers 16, 18 have increasedtoughness or hardness. In one example, friction enhancing frictionmodifiers 28 are deposited at apex or reaction areas 30 having increasedaxial thickness “T”. In another example, resins 26 having increasedtoughness or hardness are deposited by the print array 20 at areas ofthe base layer 14 where the first and second fibers 16, 18 cross over orunder one another. That is, at areas of the base layer 14 where thefirst and second fibers 16, 18 intersect, there is a potential for thefirst and second fibers 16, 18 to move relative to one another. When thefirst and second fibers 16, 18 move relative to one another, there thefirst and second fibers 16, 18 can cause frictional wear on each other.Moreover, if the first and second fibers 16, 18 are movable relative toone another, the friction-disc 10 may decay and/or become damaged andtherefore, become less effective. As a result, the print array 20applies a resin 26 having increased toughness or hardness to bothimmobilize the first and second fibers 16, 18, relative to each other,and to provide additional strength and stability to the apex areas 30 ofthe base layer 14 of the friction disc 10. In combination, because apexareas 30 of the base layer 14 are formed by areas of intersection of thefirst and second fibers 16, 18, and because the apex areas 30 have anincreased axial thickness “T”, the apex areas 30 will come into contactwith a pressure plate 32 before the rest of the base layer 14 duringuse. Therefore, it is desirable to provide the apex areas 30 withincreased strength and a predetermined coefficient of friction so thatthe friction-disc 10 operates properly and according to designparameters. Moreover, a bond compliant resin 26 is used at the interface34 between the base layer 14 and the base friction plate 12 to ensure astrong bond between the base layer 14 and the base friction plate 12. Astrong bond between the base layer 14 and the base friction plate 12 isnecessary in order to reduce the potential for friction-disc 10 failuredue to loss or failure of the friction material of the base layer 14.

In several aspects, the print array 20 deposits the plurality ofadditives 24 at predetermined locations on the base layer 14. In someaspects, by adjusting the flow rate or speed, viscosity, and density ofthe plurality of additives 24, as well as a duration of deposition asthe print array 20 operates, the manner in which the plurality ofadditives 24 is deposited on the base layer 14 can be dynamicallyadjusted. That is, the print array 20 dynamically deposits frictionenhancing materials at the apex areas 30 while also depositing resins 26having increased hardness at intersections of the first and secondfibers 16, 18, and also depositing a bond compliant resin 26 at theinterface 34 between the base layer 14 and the base friction plate 12.

In some applications, in order to improve the smoothness, gradualness,or progressiveness with which the friction-disc 10 engages with thepressure plate 32, a coefficient of friction that varies with the radiusof the friction-disc 10 may be desirable. In some examples thetransmission is an automatic transmission with a torque converterclutch, and the pressure plate 32 may be better described as a cover 32having a reaction surface. In other examples the transmission may have amulti-plate clutch arrangement in either manual or automatic forms.However, each of the friction-discs 10 making up the multi-plate clutcharrangement may be constructed in substantially the same manner withsubstantially the same componentry as described herein without departingfrom the scope or intent of the present disclosure. In the example ofFIGS. 1A-10, the coefficient of friction can be managed by carefullydepositing friction modifiers 28 at specific radial distances on thefriction-disc 10. Thus, in the example of FIGS. 1A-10, each of theplurality of additives 24 is applied to the base layer 14 in atwo-dimensional operation. That is, the print array 20 operates as ahigh-density linear print mechanism, depositing a first frictionmodifier 28′ in a customized quantity and composition to the apex areas30 where the first fibers 16 of the woven carbon base layer 14 aredisposed overtop the second fibers 18. Similarly, a customized quantityand type of a second friction modifier 28″ or resin 26 is deposited tothe apex areas 30 where the second fibers 18 of the woven carbon baselayer 14 are disposed overtop the first fibers 16.

With specific reference to FIG. 10, the friction-disc 10 is shown aspressure is applied following the direction of arrow “E”. As the amountof pressure is increased, thereby forcing the friction-disc 10 tocontact the pressure plate 32, the woven carbon material of the baselayer 14 warps. As the woven carbon base layer 14 warps, both the apices30 of the first and second fibers 16, 18 progressively contact andinteract with the pressure plate 32. In some examples, by progressivelyincreasing a contact surface area between the friction-disc 10 and thepressure plate 32, a smooth and progressive engagement of thefriction-disc 10 can be achieved.

Turning to the example of FIGS. 2A-2C, each of the plurality ofadditives 24 is also applied to the base layer 14 in a two-dimensionaloperation. In the example of FIGS. 2A-2C, unlike the woven carbon baselayer 14 of FIGS. 1A-10, the base layer 14 is composed of a compositematerial. Depending on the application for which the friction-disc 10 isintended, a woven carbon base layer 14 is not required. As describedpreviously, and as shown in FIG. 2C, in some aspects, the friction-disc10 flexes under load. That is, as pressure is progressively applied tothe friction-disc 10 along arrow “E”, the substantially planar, annularfriction-disc 10 deflects out of the substantially planar shape. Likethe example of FIGS. 1A-10, in order to improve the smoothness,gradualness, or progressiveness with which the friction-disc 10 engageswith the pressure plate 32, a coefficient of friction that varies withthe radius of the friction-disc 10 may be desirable. Therefore, thecoefficient of friction can be managed by carefully depositing frictionmodifiers 28 at specific radial distances on the friction-disc 10. Inthe example of FIG. 2A-2C, the first friction modifier 28′ is applied toan inner radial portion 36 of the friction-disc 10, while the secondfriction modifier 28″ is deposited to an outer radial portion 38 of thefriction-disc 10. Additionally, in order to aid the progressiveness withwhich the friction-disc 10 engages with the pressure plate 32, athickness or depth “d” of the first and second friction modifiers 28′,28″ is largest at an inner radius 40 of the friction-disc 10 and tapersto a minimum at an outer radius 42 of the friction-disc 10. That is, byincluding a tapering thickness or depth “d” of friction modifiers 28′,28″, a gradually increasing small portion of the friction modifiers28′,28″ may engage with the pressure plate 32 under circumstances werecarefully modulated smooth engagement is desirable. Similarly, undermore aggressive use, because the friction-disc 10 can flex under load,substantially the entire radial extent of the friction modifiers 28′,28″ initially engages with the pressure plate 32 so that thefriction-disc 10 and the pressure plate 32 abruptly engage and move withone another.

In some circumstances, producing substantially planar, annularfriction-discs 10 may not be feasible for material, cost, or otherreasons. Thus, depending on the application, the productioncapabilities, cost limitations, and so forth, in some examples it isdesirable to produce the friction-disc 10 by way of a series ofinterlocking arcuate segments 44. Turning now to FIGS. 3A and 3B, andwith continuing reference to FIGS. 1A-2B, a third example of thefriction-disc 10 is shown. Unlike the friction-discs 10 of FIGS. 1A-2B,the friction-disc 10 of FIGS. 3A and 3B is formed of a plurality ofinterlocking arcuate segments 44. Each of the plurality of interlockingarcuate segments 44 are composed of substantially the same structuralcomponents as described above with respect to FIGS. 1A-2B. That is, theinterlocking arcuate segments 44 include a base friction plate 12 bondedto and supporting a base layer 14. Furthermore, in some examples, thebase layer 14 is composed of a woven carbon material, while in otherexamples, the base layer 14 is composed of a composite material formedon or otherwise bonded to the base friction plate 12. In the example ofFIG. 3A, a portion of a first arcuate segment 46 is shown, ending at afirst end 48. The first end 48 includes a joint surface 50 with areceiving portion 52. A portion of a second arcuate segment 54 is alsoshown in FIG. 3A. The second arcuate segment 54 extends to a second end56. Like the first end 48, the second end 56 includes a joint surface50. However, the second end 56 also includes a protruding portion 58.The protruding portion 58 is shaped and sized to interlock and immovablyengage with the receiving portion 52. In the example of FIG. 3A, thereceiving portion 52 and the protruding portion 58 are shown as asubstantially round lobate receptacle and protrusion, respectively.However, it should be appreciated that the receiving portion 52 and theprotruding portion 58 may take other shapes such as finger joints,mortise and tenon joints, splice joints, tongue and groove joints,dovetail joints, or any other such interlocking and immobilizing jointswithout departing from the scope or intent of the present disclosure.

Aside from a mechanical joint between the first arcuate segment 46 andthe second arcuate segment 54, the axial construction of thefriction-disc 10 of FIGS. 3A and 3B is substantially similar to that ofFIGS. 1A-2B. However, in some aspects, because multiple interlockingarcuate segments 44 make up the friction-disc 10 of FIGS. 3A and 3B,some additional structural reinforcement to the joint areas isdesirable. To improve the structural strength, robustness, reliability,and longevity of the multi-part friction-disc 10, the print array 20deposits a predetermined quantity of a structural resin 26 at or on thejoint surfaces 50 of the first and second arcuate segments 46, 54. Thatis, each of the plurality of additives 24 is applied to the base layer14 in a three-dimensional operation to ensure structural requirementsfor the friction-disc 10 are met. In some examples, the print array 20also applies additional structural resin 26 along at least a portion ofthe inner radius and the outer radius 40, 42 of the friction-disc 10.More generally, the print array 20 deposits the plurality of additives24 at predetermined locations on the base layer 14. By adjusting theflow rate or speed, viscosity, and density of the additives 24, as wellas a duration of deposition as the print array 20 operates, the mannerin which the additives 24 are locally deposited overtop the base layer14 can be dynamically adjusted. In the example of FIGS. 3A and 3B,therefore, the dynamic adjustment of the flow of additives 24 throughnozzles 22 of the print array 20 is adjusted to provide structuralreinforcement to the joint surfaces 50 of the first and second arcuatesegments 46, 54.

Turning now to FIGS. 4A and 4B each of the plurality of additives 24 isalso applied to the base layer 14 in a three-dimensional operation. Thatis, the plurality of additives 24 are deposited on and in someinstances, axially impregnated into the base layer 14 by the print array20. The axial deposition of the additives 24 provides latitude forstrength and frictional modifications based on the use of additives 24having differing viscosities. In an example, an additive 24 providingstructural strength and rigidity to a woven carbon base layer 14 has alow viscosity. The low viscosity allows the additive 24 to wick into anddeeply penetrate and impregnate the first and second fibers 16, 18 ofthe woven carbon material of the base layer 14. In another example,another additive 24 providing desirable frictional characteristics isdeposited by the print array 20 on the woven carbon material of the baselayer 14. In some aspects it is desirable to modify the frictionalcharacteristics of the friction-disc 10 at or near a contact surface 60where the apices 30 of the base layer 14 interact with and engage thepressure plate 32. Accordingly, the additive 24 providing desirablefrictional characteristics has a relatively high viscosity in comparisonwith the prior example of the low viscosity additive 24 providingstructural strength. The relatively high viscosity prevents the frictionmodifier 28 additive from wicking or seeping deeply into the first andsecond fibers 16, 18 of the base layer 14, thereby ensuring that thefriction modifier 28 remains substantially at or near the apices 30 ofthe base layer 14 that form the contact surface 60.

Turning now to FIG. 5 a method for manufacturing friction-discs 10 isshown and generally indicated by reference number 100. The method 100begins at box 102 where a laminated friction-disc 10 material isreceived on a production line. The laminated friction-disc 10 materialis generally provided in the form of long, continuous rolls or plates ofstock material. In some aspects, an adhesive or bonding material isapplied to the friction-disc 10 material in the raw stock material form.That is, an adhesive is applied to a core stock material made of ametallic or ceramic material, such as a steel plate material. At block104, the laminated friction disc 10 material is fed into a cutting toolor machine. In some examples, the cutting tool is a machine such as apress, a die cutting machine, or the like. In some examples, thelaminated friction disc 10 material is cut into substantially planarannular discs 11. In other examples, the laminated friction-disc 10material is cut into a plurality of arcuate segments 44 havinginterlocking features. Depending on the application, the productionrequirements and capabilities, and on other factors, at block 106 thelaminated friction disc 10 material is then placed into the print array20 and a plurality of additives 24 are thereafter deposited onto thefriction-disc 10 or arcuate segments of the friction-disc 10. In someexamples, the print array 20 operates substantially as a high densitylinear print mechanism. That is, the print array 20 moves linearlyacross the friction-disc 10 depositing the additives 24 on thefriction-disc 10 while the friction-disc 10 is moved in a linear fashionpast and perpendicular to the motion of the print array 20. In someaspects, when the array 20 operates as a high density linear printmechanism, the movements of the print array 20 and the friction-disc 10are similar to the movements of a print head and a piece of paperthrough an inkjet printer, respectively. In other examples, the printarray 20 operates as a translational printer. That is, the print array20 moves over the friction-disc 10 in all directions while thefriction-disc 10 is held stationary. In several aspects, when the printarray 20 operates as a translational printer, the movements of the printarray 20 are similar to those of a 3-D printer. Once the plurality ofadditives 24 have been deposited on the friction-disc 10 at block 108the substantially planar annular friction-discs 10 or the arcuatesegments 44 of the friction-discs 10 are loaded onto and bonded to thebase friction plate 12. However, in some examples, as shown at block 110it is preferable load and bond the substantially planar annularfriction-discs 10 or the arcuate segments 44 of the friction-discs 10 tothe base friction plate 12 prior to modifying the frictional andstructural characteristics of the base layer 14 of the friction-disc 10.At block 112, once the friction-discs 10 have been assembled to the basefriction plate 12, the entire friction-disc 10 is loaded into the printarray 20 as a unit and the plurality of additives 24 are thereinafterdeposited on the base layer 14 of the friction-disc 10. Once thefriction-discs 10 have been loaded, bonded, and the plurality ofadditives 24 have been applied, the method 100 proceeds from blocks 108and/or 112 to block 114 where the friction-discs 10 are assembled withother transmission components within a transmission case (not shown) foruse in a motor vehicle. At block 116 the method 100 ends.

A system and method for producing an automotive friction material withoptimized multi-dimensional construction of the present disclosureoffers several advantages. These include improved performance, bettercontrol of distribution of raw materials used during friction materialmanufacturing, and optimization of friction performance and internalstructural strength, while decreasing manufacturing obstacles andmaintaining or reducing costs. The description of the present disclosureis merely exemplary in nature and variations that do not depart from thegist of the present disclosure are intended to be within the scope ofthe present disclosure. Such variations are not to be regarded as adeparture from the spirit and scope of the present disclosure.

What is claimed is:
 1. A method for producing an automotive frictionmaterial with optimized multi-dimensional construction comprises:receiving a base friction-disc material; cutting the base friction-discmaterial to a predetermined size and shape; assembling the cut, sized,and shaped base friction-disc material; bonding the base friction-discmaterial to a base friction plate; and utilizing a multi nozzle printingarray to deposit friction enhancing materials overtop a reaction surfaceof the base friction-disc material.
 2. The method of claim 1 whereinreceiving the base friction-disc material further comprises receiving acontinuous roll or flattened stock forming the base friction-discmaterial.
 3. The method of claim 1 wherein the base friction-discmaterial is a woven material.
 4. The method of claim 1 wherein the basefriction material is a composite material.
 5. The method of claim 1wherein cutting the base friction-disc material further comprisesutilizing a die to cut interlocking arcuate segments or annular rings ofbase friction-disc material from the base friction-disc material.
 6. Themethod of claim 5 wherein assembling the sized and shaped cut basefriction-disc material further comprises connecting interlocking arcuatesegments to form complete annular rings of base friction-disc material.7. The method of claim 1 wherein bonding the base friction-disc materialto the base friction plate further comprises injecting a bondingmaterial between the base friction-disc material and the base frictionplate.
 8. The method of claim 1 wherein utilizing a multi nozzle printarray further comprises providing a supply of a plurality of frictionenhancing materials to nozzles of the print array, wherein the pluralityof friction enhancing materials include friction modifiers and resins.9. The method of claim 1 wherein utilizing a multi nozzle print arrayfurther comprises depositing structural resin to precise predeterminedlocations on the base friction-disc material in a high density linearprinting process or a translational printing process.
 10. The method ofclaim 1 further comprising dynamically adjusting material properties ofthe friction enhancing materials as the multi nozzle print arraydeposits the friction enhancing materials on the reaction surface of thebase friction-disc material.
 11. The method of claim 10 whereindynamically adjusting material properties of the friction enhancingmaterials further comprises actively and dynamically controlling aduration of deposition, a viscosity, a density, and a flow speed or flowrate of the friction enhancing materials through the multi nozzle printarray.
 12. The method of claim 1 wherein utilizing a multi nozzle printarray to deposit friction enhancing materials overtop a reaction surfaceof the base friction-disc material further comprises dynamicallyadjusting a depth of the friction enhancing materials as the frictionenhancing materials are deposited on the base friction-disc material.13. A method for producing an automotive friction material withoptimized multi-dimensional construction comprises: receiving acontinuous roll or flattened stock base friction-disc material composedof a woven carbon material or a composite material; cutting the basefriction-disc material to a predetermined size and shape, thepredetermined size and shape being interlocking arcuate segments orannular rings of base friction-disc material cut from the basefriction-disc material stock; and utilizing a multi nozzle printingarray to deposit friction enhancing materials overtop a reaction surfaceof the base friction-disc material.
 14. The method of claim 13 furthercomprising assembling the annular rings or assembling the interlockingarcuate segments to form annular ring, and utilizing a bonding materialbetween the annular rings of base friction-disc material and a basefriction plate to permanently bond the annular rings of basefriction-disc material to the base friction plate.
 15. The method ofclaim 13 wherein utilizing a multi nozzle print array further comprisesproviding a supply of a plurality of friction enhancing materials tonozzles of the print array, wherein the plurality of friction enhancingmaterials include friction modifiers and resins.
 16. The method of claim13 wherein utilizing a multi nozzle print array further comprisesdepositing a structural resin at precise predetermined locations on thebase friction-disc material in a high density linear printing process ora translational printing process, and dynamically adjusting a durationof deposition, a viscosity, a density, a flow speed or flow rate, and amaterial composition of the friction enhancing materials as the multinozzle print array deposits the friction enhancing materials on the basefriction-disc material.
 17. The method of claim 13 further comprisingdynamically adjusting a depth of the friction enhancing materials as thefriction enhancing materials are deposited on the base friction-discmaterial.
 18. The method of claim 13 wherein utilizing a multi nozzleprint array further comprises depositing a structural resin into jointsbetween interlocking arcuate segments of base friction-disc material.19. A method for producing an automotive friction material withoptimized multi-dimensional construction comprises: receiving acontinuous roll or flattened stock base friction-disc material composedof a woven carbon material or a composite material; cutting the basefriction-disc material to a predetermined size and shape, thepredetermined size and shape being interlocking arcuate segments orannular rings of base friction-disc material cut from the basefriction-disc material; bonding the annular rings to a base frictionplate, or assembling the interlocking arcuate segments to form annularrings and bonding the resulting annular rings to the base friction plateby utilizing a bonding material between the annular rings of basefriction-disc material and the base friction plate to permanently bondthe annular rings of base friction-disc material to the base frictionplate; providing a supply of a plurality of friction enhancing materialsto nozzles of a multi nozzle print array, wherein the plurality offriction enhancing materials include friction modifiers and resins;utilizing the multi nozzle printing array to deposit a structural resinat precise predetermined locations on the base friction-disc material ina high density linear printing process or a translational printingprocess, and dynamically adjusting a duration of deposition, aviscosity, a density, a flow speed or flow rate, and a materialcomposition of the friction enhancing materials as the multi nozzleprint array deposits the friction enhancing materials on the basefriction-disc material; and dynamically adjusting a depth of thefriction enhancing materials as the friction enhancing materials aredeposited on the base friction-disc material, wherein the multi nozzleprinting array deposits friction enhancing materials overtop a reactionsurface of the base friction-disc material.
 20. The method of claim 19wherein utilizing a multi nozzle print array further comprisesdepositing a structural resin into joints between interlocking arcuatesegments of base friction-disc material.